DODGE RAM SRT-10 2006 Service Repair Manual

DUCT-INSTRUMENT PANEL DEMISTER
REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the
battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to
take the proper precautions could result in an accidental airbag deployment and possible personal injury or
death.
NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage.
1. Remove the instrument panel and place it on a
workbench (Refer to 23 - BODY/INSTRUMENT
PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
2. Remove the radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL).
3. Remove the defroster duct (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION/DUCT-DE-
FROSTER - REMOVAL).
4. Remove the two screws (1) that secure the center
distribution duct (2) to the instrument panel support
(3) and remove the duct.
5. Disconnect the right side instrument panel duct
adapter (2) from the right side instrument panel
duct (1) and remove the adapter.
6. Remove the screw that secures each intermediate
demister duct (3 and 4) to the instrument panel
cover.
7. Disconnect the intermediate demister ducts from
the demister ducts and remove the intermediate
ducts.
8. Disconnect the left side instrument panel duct
adapter (6) from the right side instrument panel
duct (5) and remove the adapter
9. Remove the instrument panel cover (Refer to 23 -
BODY/INSTRUMENT PANEL/COVER-INSTRU-
MENT PANEL - REMOVAL).
10. Remove the two screwsthat secure each demis-
ter duct to the instrument panel cover and remove
the ducts.

INSTALLATION
1. Position the demister ducts onto the instrument
panel cover.
2. Install the two screws that secure each demister
duct to the instrument panel cover. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
3. Install the instrument panel cover (Refer to 23 -
BODY/INSTRUMENT PANEL/COVER-INSTRU-
MENT PANEL - INSTALLATION).
4. Position the left side instrument panel duct adapter
(6) into the instrument panel and connect it to the
left panel duct.
5. Position the intermediate demister ducts (3 and 4)
into the instrument panel and connect them to the
demister ducts.
6. Install the screw that secures each intermediate
demister duct to the instrument panel cover.
Tighten the screws to 2.2 Nꞏm (20 in. lbs.).
7. Position the right side instrument panel duct
adapter (2) into the instrument panel and connect it to the right panel duct.
8. Position the center distribution duct (2) to the
instrument panel support (3).
9. Install the two screws (1) that secure the center
distribution duct to the instrument panel support.
Tighten the screws to 2.2 Nꞏm (20 in. lbs.).
10. Install the defroster duct (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION/DUCT-
DEFROSTER - INSTALLATION).
11. Install the radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION).
12. Install the instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).

HOUSING-HVAC
DESCRIPTION
All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a
single unit mounted within the passenger compartment. The HVAC housing assembly consists of the following:
HVAC housing— The HVAC housing consists of an upper housing (7) and a lower housing (10) that are
attached together by screws and is mounted to the dash panel behind the instrument panel. The HVAC hous-
ing contains the heater core (9), A/C evaporator (15), blend-air and mode-air doors, and has mounting provi-
sions for the air-door actuators (3, 5, 6 and 8), floor distribution duct (4), blower motor (13), blower motor
resistor, foam seals (12, 14 and 16) and the HVAC wire harness (11).
Air inlet housing— The air inlet housing (1) is mounted to the right end of the HVAC housing andcontains
the recirculation-air door and has mounting provisions for the recirculation door actuator (2).
The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is
allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actua-
tors while the single zone system uses only one blend door actuator.
The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and
dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge
air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost
immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors
which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recir-
culation door actuator operates the recirculation-air door which closesoff the fresh air intake and recirculates the air
already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC
wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning
the blower wheel within the HVAC housings at the selected speed by use of theblower motor resistor.
The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evap-
orator, evaporator temperature sensor, blend-air and mode-air doors. The air inlet housing must be removed from
HVAC housing and disassembled for service of the recirculation-air door.

REMOVAL
HVAC HOUSING ASSEMBLY
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the
negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to
take the proper precautions could result in accidental airbag deploymentand possible personal injury or
death.
NOTE: The HVAC housing must be removedfrom the vehicle and disassembled for service of the A/C evap-
orator, evaporator temperature sensor, mode-air and blend-air doors.
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOL-
ING SYSTEM DRAIN).
3. Disconnect and isolate the negative battery cable.
4. Disconnect the A/C liquid line and the A/C accumu-
lator from the A/C evaporator (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/LINE-A/C
LIQUID - REMOVAL) and (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/ACCUMULA-
TOR-A/C - REMOVAL).
5. Disconnect the heater hoses from the heater core
tubes.
6. Remove the powertrain control module (PCM) to
gain access to the two nuts (3) that secure the
HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE - REMOVAL).

7. On Mega Cab models, remove the floor console
duct (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/DUCT-FLOOR CONSOLE -
REMOVAL).
8. Remove the instrument panel from the passenger
compartment (Refer to 23 - BODY/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
9. Remove the bolt (5) that secures the HVAC hous-
ing (4) to the floor bracket (6).
10. Remove the two nuts (3 and 7) that secure the
HVAC housing to the passenger compartment
side of the dash panel (1).
11. Pull the HVAC housing assembly rearward and
remove the housing assembly from the passenger
compartment.
12. If required, remove the fresh air inlet (2) from the
dash panel (1).
AIR INLET HOUSING
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the
negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to
take the proper precautions could result in accidental airbag deploymentand possible personal injury or
death.
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the
recirculation-air door.
1. Remove the HVAC housing assembly (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/HOUSING-HVAC - HVAC HOUSING ASSEM-
BLY - REMOVAL).
2. Remove the recirculation door actuator (1) from the
air inlet housing (2) and disconnect the HVAC wire
harness (4) from the actuator.
3. Remove the two screws (3) that secure the rear of
the air inlet housing to the top of the HVAC housing
(5).

4. Release the two retaining clips (1) that secure the
front of the air inlet housing (2) to the top of the
HVAC housing (3) and remove the air inlet housing.
NOTE: If the foam seal on the air inlet housing is
deformed or damaged, it must be replaced.
5. If required, disassemblethe air inlet housing (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HOUSING-HVAC ASSEMBLY - AIR INLET
HOUSING - DISASSEMBLY).
DISASSEMBLY
HVAC HOUSING
NOTE: The HVAC housing must be removedfrom the vehicle and disassembled for service of the A/C evap-
orator, evaporator temperature sensor, mode-air and blend-air doors.
1. Remove the HVAC housing assembly and place it
on a workbench (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION /HOUSING-HVAC
- HVAC HOUSING ASSEMBLY - REMOVAL).
2. Disconnect the HVAC wire harness connectors
from the mode door actuators (1), blend door
actuators (2) and the recirculation door actuator
(3).
3. Remove the screws that secure the mode door
actuators and the blend door actuators to the
HVAC housing (5) and remove the actuators.
4. Remove the screws that secure the recirculation
door actuator to the air inlet housing (4) and
remove the actuator.

5. Disconnect the wire harness connectors (1 and 3)
from the blower motor resistor (7) and the blower
motor (2).
6. Remove the screws (4)that secure the blower
motor to the HVAC housing (5) and remove the
blower motor.
7. Remove the screws (6)that secure the blower
motor resistor to the HVAC housing and remove
the resistor.
8. Disconnect the HVAC wire harness (1) from the
evaporator temperature sensor (2) and remove the
HVAC wiring harness from the HVAC housing (4).
9. Remove the air inlet housing (3) from the HVAC
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HOUSING-HVAC - AIR
INLET HOUSING - REMOVAL).
10. Remove the two screws (1) that secure the panel/
floor door outlet (2) to the top of the HVAC hous-
ing (4).
NOTE: If the foam seal on the panel/floor door out-
let is deformed or damaged, it must be replaced.
11. Release the two retaining tabs (3) that secure the
panel/floor door outlet to the front of the HVAC
housing and remove the door outlet.

12. Remove the three screws (1) that secure the pan-
el/floor door assembly (2) to the top of the HVAC
housing (3) and remove the door assembly.
13. To remove the panel/floor-air doors (1) from the
panel/floor door plate (2), first carefully release
the retaining tabs of actuator coupler (3) located
on the inside surface of the door plate and pull
the actuator coupler out of the pivot shaft of the
panel/floor-air doors.
NOTE: If the seals on the air doors is deformed or
damaged, the air doors must be replaced.
14. Remove the panel/floor-air doors from the panel/
floor door plate.

NOTE: If the foam seal for the heater core tubes is
deformed or damaged, the seal must be replaced.
15. Remove the foam seal from the heater core
tubes.
16. If equipped with the dual zone heating-A/C sys-
tem, remove the linkage rod (4) to gain access to
theheatercore(3).
17. Remove the two screws (1)that secure the heater
core tube bracket (2) to the HVAC housing and
remove the bracket.
18. Carefully pull the heater core out of the front of
the HVAC housing.
19. Inspect all heater core foam seals and replace as
required.
20. Remove the screws (3) that secure the floor dis-
tribution duct (1) to the bottom of the HVAC hous-
ing (2).
21. Remove the floor distribution duct from the HVAC
housing.

22. Carefully disconnect the linkage rod (1) from the
two blend-air door levers (2) located on the back
of the HVAC housing (3).
NOTE: If the foam seal for the evaporator conden-
sate drain tube is deformed or damaged, the seal
must be replaced.
23. Remove the foam seal (4) from the evaporator
condensate drain tube (5).
24. Remove the fifteen screws (6) that secure the
upper and lower HVAC housing halves together
and separate the housing halves.
25. Release the three retaining tabs (1) that secure
the lower blend door assembly (2) to the lower
half of the HVAC housing (3) and remove the door
assembly.
26. Release the three retaining tabs that secure the
upper blend door assembly to the upper half of
the HVAC housing and remove the door
assembly.
27. To remove the blend-air doors (1) from each
blend door plate (2), first carefully release the
retaining tabs of actuator coupler (3) located on
the inside surface of the door plate being serviced
and pull the actuator coupler out of the pivot shaft
of the blend-air doors.
NOTE: If the seals on the air doors is deformed or
damaged, the air doors must be replaced.
28. Remove the blend-air doors from the blend door
plates.